Integrated experimental and thermodynamic modelling research methodology for metallurgical slags with examples in the copper production field

Jak, Evgueni (2012). Integrated experimental and thermodynamic modelling research methodology for metallurgical slags with examples in the copper production field. In: Proceedings of the Ninth International Conference on Molten Slags, Fluxes and Salts (MOLTEN12). Ninth International Conference on Molten Slags, Fluxes and Salts (MOLTEN12), Beijing, China, (). 27-30 May 2012.

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Author Jak, Evgueni
Title of paper Integrated experimental and thermodynamic modelling research methodology for metallurgical slags with examples in the copper production field
Conference name Ninth International Conference on Molten Slags, Fluxes and Salts (MOLTEN12)
Conference location Beijing, China
Conference dates 27-30 May 2012
Proceedings title Proceedings of the Ninth International Conference on Molten Slags, Fluxes and Salts (MOLTEN12)
Place of Publication Beijing, China
Publisher The Chinese Society for Metals
Publication Year 2012
Sub-type Fully published paper
Total pages 28
Collection year 2013
Language eng
Formatted Abstract/Summary
Recent advances of coupled experimental and thermodynamic modelling research on phase equilibria, thermodynamics and viscosities of copper and other metallurgical slag systems, and experiences of implementation of the advanced research outcomes into industrial practice are summarised. An outline of key issues derived from many years experience in continuing development and application of both experimental, thermodynamic and viscosity modelling research is presented. Particular emphasis is given to the details of the research methodologies, analysis of reasons for uncertainties and the ways to continuously improve the accuracy of both studies. The ways how the advanced research tools can be implemented into industrial operations are presented with examples on copper production slag systems.

Experimental part of the study involves high temperature equilibration in controlled gas atmospheres, rapid quenching and direct measurement of equilibrium phases with electron probe X-ray microanalysis (EPMA). Thermodynamic modelling undertaken using computer package FactSage with the quasi-chemical model for the liquid slag phase is closely integrated with the parallel experimental research. Experiments are planned to provide specific data for thermodynamic model development as well as for pseudo-ternary liquidus diagrams which can be used directly by process operators. Thermodynamic assessments are used to identify priorities for experiments. Experimental and modelling studies are combined into an integrated research program contributing to and enhancing outcomes of each other and of the overall program.

The continuous development of experimental methodologies have brought significant advances. Importantly, these novel approaches enable measurements to be made in systems that could not previously be characterised, for example, due to uncontrollable reactions with container materials or changes in bulk composition due to vapour phase reactions. The approach, however, requires particular attention to ensure accurate information is obtained. An ongoing dedicated program of improving accuracy of all possible elements of the research revealed a number of possible sources of uncertainties and the ways developed to mitigate those shortcomings are systematically summarised in this paper.

The thermodynamic modelling has progressed significantly, and achieved a level of prediction of phase equilibria and thermodynamics of complex multi-component multi-phase systems with improved accuracy. The adequate description of the systems however requires a combination of various types of data and still demands continuous further development.

The outcomes of both experimental and modelling studies are applied to assist in improvements of the industrial copper production. High certainty of the predictions of the behaviour of complex industrial processes provides a strong basis for optimisation of operations. The stage of implementation of the outcomes of the laboratory experimental and theoretical thermodynamic modelling, however, is frequently overlooked, but requires high level of research expertise to establish the actual conditions in the real industrial process and relate them to the advanced laboratory and theoretical research tools. Examples of the applications are given in the paper.
Keyword Copper smelting
Slag
Phase equilibria
Thermodynamic modelling
Liquidus
Minor elements distribution
Q-Index Code E1
Q-Index Status Confirmed Code
Institutional Status UQ
Additional Notes Paper KN W077.

Document type: Conference Paper
Collections: School of Chemical Engineering Publications
Official 2013 Collection
 
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Created: Thu, 11 Apr 2013, 23:05:42 EST by Professor Evgueni Jak on behalf of School of Chemical Engineering